Strapping system

ABSTRACT

A strapping system includes a flexible, textile strap having locking elements. The strap defines an attachment portion upon which a reinforcement element formed from a solid mass of polymeric material inseparably and integrally secures. The locking elements of the strap are embedded at least in part into the thickness of a reinforcement element.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority from U.S. provisional patent applications 61/308,079, filed on Feb. 25, 2010, and 61/285,538, filed on Dec. 10, 2009, the entirety of each of these provisional applications is incorporated herein

FIELD OF THE INVENTION

The invention is directed to strapping systems having polymeric reinforced sections, padding parts, and other features integrally and inseparably secured to a textile strap, preferably for use in an orthopedic or prosthetic device.

BACKGROUND

In strapping systems for use in products such as but not limited to orthopedic devices, often significant loads are applied to the straps. Particularly, since straps in the strapping system are weaker or thinner than a stronger base to the orthopedic product, the straps may tear or weaken over a period of use due to a more rigid fastener securing the strap to the base. As a result, metal eyelets or grommets are often employed to reinforce the strap, or intermediary brackets are used between the base of the product and the strap so as to reduce the wear on the strap. Alternatively, there is no reinforcement of the strap and the strap is secured to the base merely by a fastener.

An example of an orthopedic device is found in U.S. patent application publication 2009/0287127, which is incorporated herein by reference. In this orthopedic device, embodied as a circumferential walker, a strap is mounted to a shell or base formed from a rigid plastic. The strap is secured to the shell by rivets. A grommet may be used to reinforce an opening in the strap to allow for the fastener to extend therethrough and secure the strap to the base. The combination of the grommet and rivet may rub against the shell, possibly leading to undesirable wear of the shell, and likewise causing discomfort to the wearer.

For the foregoing reasons, there is a need to provide an improved strapping system that provides for reinforcement of a strap that securely retains a strap to a fastener and a base while maintaining sufficient durability and strength for requisite applications.

SUMMARY

In accordance with an embodiment of the disclosure, a strapping system includes a flexible, textile strap having locking elements. The strap defines an attachment portion upon which a reinforcement element inseparably and integrally secures. The locking elements of the strap are embedded at least in part into the thickness of a reinforcement element.

In a variation of the strap, the locking elements are formed along a single side of the strap. The reinforcement element may be secured to a first side of a first end portion of the strap, or alternatively, the reinforcement element is secured to first and second sides of a first end portion of the strap.

In another variation, an opening extends through a thickness of the reinforcement element and the strap. The reinforcement element may further define a slot protruding therefrom either coincident with the strap. According to another variation, the reinforcement element defines an extension end portion arranged beyond an end portion of the strap which may define the slot. A first surface of the reinforcement element can have at least one gripping tab extending therefrom.

The reinforcement element may be contoured in a predetermined shape, and is flexible and resiliently bending from the predetermined shape to an additional shape upon the exertion of a force. The reinforcement element will return to the predetermined shape upon removal of the force. For example, the reinforcement element may have an arcuate shape in a first configuration formed as at least part of a cuff. The cuff is resilient to bending upon application of a force and substantially returns to the first configuration upon release of the force.

The strap may have different properties from the reinforcement element. For example, the strap can be substantially more flexible than the reinforcement element, where the reinforcement element can be flexible, rigid or substantially rigid. In an example, the reinforcement element may be substantially compressible, and particularly compressible relative to the strap. In another example, the reinforcement element is an elongate frame element formed from a substantially rigid material.

The reinforcement element may be secure along any part or length of a strap. The reinforcement element can form a structure that secures to a generally intermediate portion of a strap. The structure forms a slot that permits the extension of a second strap therethrough. In another variation, the reinforcement element forms a structure and secures to a generally intermediate portion of a strap. The first structure forms at least one slot along an exterior side thereof, and a second strap including a second structure having an engaging element is arranged to slidably interlock with the slot of the first structure. According to another variation, the reinforcement element forms a structure encasing opposed sides of the strap along an intermediate portion of the strap.

The numerous advantages, features and functions of the various embodiments of the strapping system will become readily apparent and better understood in view of the following description and accompanying drawings. The following description is not intended to limit the scope of the strapping system, but instead merely provides exemplary embodiments for ease of understanding.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view showing an embodiment of a strapping system.

FIG. 2A is a schematic view according to the strapping system of FIG. 1 mounted on a base portion.

FIG. 2B is a perspective view of an exemplary orthopedic walker having the strapping system of FIG. 1.

FIG. 3A is a plan view showing an embodiment of a strapping system.

FIG. 3B is a cross-sectional view taken along line 3B-3B in FIG. 3A.

FIG. 4A is a plan view showing an embodiment of a strapping system.

FIG. 4B is a cross-sectional view taken along line 4B-4B in FIG. 4A.

FIG. 4C is a cross-sectional view taken along line 4C-4C in FIG. 4A.

FIG. 5 is a plan view showing an embodiment of a strapping system.

FIG. 6 is an elevational view showing an embodiment of a strapping system located on an orthopedic device.

FIG. 7A is a plan view showing an embodiment of a strapping system.

FIG. 7B is a sectional view taken along line 7B-7B in FIG. 7A.

FIG. 8 is a plan view showing an embodiment of a strapping system.

FIG. 9 is a plan view showing an embodiment of a strapping system.

FIG. 10 is a plan view showing an embodiment of a strapping system including the strapping system in FIG. 9 secured therewith.

FIG. 11 is a plan view showing an embodiment of a strapping system.

FIGS. 12A and 12B are elevational views showing an embodiment of a strapping system.

FIG. 13 is a plan view showing an embodiment of a strapping system.

FIG. 14 is an elevational view of an embodiment of a strapping system.

FIG. 15 is a plan view of an embodiment of a strapping system.

FIG. 16A is perspective view of an embodiment of a strapping system.

FIG. 16B is a perspective view of the strapping system of FIG. 16A on a structure.

FIG. 17 is a plan view of an embodiment of a strapping system.

FIG. 18 is a plan view of an embodiment of a strapping system.

FIG. 19A is a plan view of an embodiment of a strapping system.

FIG. 19B is a sectional view taken along line 19A-19A in FIG. 19B.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

In accordance with a first embodiment of a strapping system shown in FIG. 1, a strapping system 10 includes an elongate textile based strap 12 and a reinforcement element 14, preferably formed from a solid mass of a molded polymeric material, secured at a predetermined attachment portion or location on the strap 12, preferably an end portion. The strap 12 is flexible and compliant whereas the reinforcement element 14 has greater rigidity than the strap 12. The reinforcement element 14 is integrally secured and generally inseparable from the strap 12 without any fastener, welding (i.e., ultrasonic weld) or adhesive.

The strap 12 includes locking elements 16, such as loop from broken or unbroken loop material, which protrude from the surface of the strap 12. The reinforcement element 14 interlocks with the locking elements 16. For example, the reinforcement element 14 may be formed as a solid mass of molded material, such as Nylon, Polyurethane, Polypropylene, ABS, Acetal, Polyethylene, hard TPU or other suitable polymeric material which is not brittle and sufficiently strong for a desired application, having a thickness into which the locking elements 16 are present. Where softness or friction (such as minimizing or enhancing the friction of the reinforcement element against a base structure or for grasping by fingers) is required of the reinforcement material, preferred materials include thermoplastic polyethylene, silicone and soft thermoplastic polyurethane. When the molded reinforcement element 14 is cured, molded and thusly formed, the locking elements 16 are embedded in the thickness of the strap 12.

A preferred loop material may be any common material used to make straps, including loop material made from polypropylene, polyester, and nylon. Moreover, textiles of various types may likewise be used.

By understanding the expression “generally inseparable,” this means that the reinforcement element can only be removed from the strap with considerable exertion by effectively and wholly undesirably destroying the bond between the strap and the reinforcement element. The expression “integrally secured” connotes that the strap and the reinforcement element are formed as a unitary structure, particularly with the reinforcement element formed and melded, as in merged, with the strap through molding.

The reinforcement element 14 may have a variety of shapes and be formed from a variety of moldable materials. For example, as shown in the illustrated embodiment, the reinforcement element 14 may have a profile that corresponds in shape to the end portion of the strap 12. The reinforcement element can be molded to correspond to particular shapes either of the strap or the base structure.

In the embodiment shown herein, the reinforcement element 14 is located on a single side of the strap 12, specifically the side of the strap having the locking elements 16. In other variations, the reinforcement elements 14 may be formed on opposed sides of a strap 12.

According to the illustrated embodiment, the reinforcement element 14 is more rigid and has a greater hardness than the strap 12. In variations of the reinforcement element 14, the reinforcement element 14 may have softness and is formed generally as a padding element that is secured to a strap 12. In one variation, the reinforcement element 14 is only located at the end portion 15 of the strapping system 10 so as to allow for flexibility of the strapping system.

FIG. 1 also shows that portions of the strap 12 can include a free end reinforcement element 24 formed on an end portion 22 of the strap 12 that freely extends from any base structure. The reinforcement element 24 may include a traction texture 26, such as a protrusion, molded therein to allow for better grasping. This reinforcement element 24 is devoid of any elements or feature that would catch on hook elements since it covers the locking element, such as hook or loop material, and therefore serves as a portion of the strap that can be easily grasped to remove or unsecure the strap.

In variations to the embodiments provided herein, additional features may be formed on the reinforcement element 14. For example, a rivet structure may be formed on the reinforcement element. The rivet structure is provided to secure to a base structure of an orthopedic device.

In the following additional embodiments, any of these embodiments may be combined with a reinforcement element or similar element and a strap in the manner described in connection with the embodiment of FIGS. 1, 2A and 2B.

FIGS. 2A and 2B depict the strapping system 10 as being secured to a base structure 18 wherein the base structure 18 is exemplified as a shell belonging to an orthopedic walker as described in U.S. patent application publication 2009/0287127. Any of the straps mounted on the orthopedic walker 25 may include any of the strapping system configurations described herein. The end portion 15 of the strapping system 10 is rotatably secured to the base structure 18 wherein a fastener 21 secures the strapping system 10 to the base structure 18 and the fastener 21 extends through the opening 20 (shown in FIG. 1) formed on the reinforced end portion of the strapping system 10 including both the strap 12 and the fastener element 21, and a wall thickness of the base structure 18.

As shown in FIGS. 2A and 2B, the strap 12 may carry a D-ring attachment 23 at a free end portion while the other end portion is reinforced with the reinforcement element 14. The free end portion of is flexible whereas the reinforced end portion is substantially less flexible and/or substantially rigid. A strap mounted on an opposed side of the D-ring attachment secures to the D-ring attachment.

The strap is not limited to being textile based, but may be of any appropriate type known to the skilled person including a molded polymeric strap. The strap may be secured to the reinforcement element by means different from locking elements, such as by molding over the strap with a polymeric material and by forming a bond between the strap and the molded material. Alternatively, the reinforcement element may be adhered to the textile strap.

FIG. 2B shows how the reinforcement element (14) is contoured to a predetermined shape corresponding to the base structure (18). Specifically, the periphery of the reinforcement element (14) is defined by the shape of the end portion of the strap and the point (defined by the dashed lines) at which the strap (12) extends past the periphery of the base structure (18). From this arrangement, the reinforcement element (14) is generally flush with the periphery of the base structure (18) so as to maintain the reinforcement element (14) from extending past the base structure (18) and minimizing at least rubbing of the strap (12) itself against the base structure (18).

Another embodiment of the strapping system is depicted in FIGS. 3A and 3B. The strapping system 30 includes a strap 32 and a reinforcement element 34 secured to a portion of the strap. While depicted at an intermediate strap portion, the reinforcement element 34 may be secured to a variety of different locations along the strap 32. Peripheral edges 36 of the strap 32 are shown as extending through the strap 32.

The reinforcement element 34 may be constructed of a foamed polymeric material so as to form a cushion. In variations, the reinforcement element may be formed from any rigid, semi-rigid, flexible or soft polymeric material, depending on the desired application or purpose of the reinforcement element in combination with the strap.

FIG. 3B shows how the strap 32 may be centrally located within the thickness of the reinforcement element 34. In variations, the strap may be embedded into the reinforcement element at a variety of locations, including those closer to either one of the faces of the reinforcement element.

In another embodiment of a strapping system, FIGS. 4A-4B illustrate a dual strapping system 40 having straps 42, 44 coupled by a central reinforcement element 45, exemplified herein as a patella stabilizer or “donut.” According to this embodiment, the reinforcement element 45 defines an opening 46 and overhanging portions 48.

FIGS. 4B and 4C show the reinforcement element 45 as having a tapered thickness 47, 49 which can be arranged according to an anatomical shape. The opening 46 may be formed so as to have a non-uniform shape also including a taper. The straps 42, 44 have portions that are embedded within the overhang portions 48 of the reinforcement element 45.

FIG. 5 illustrates an embodiment of a strapping system 50 having a strap 52 and a grasping element 58 formed at an end the strap 52. The strapping system 50 includes a section of hook material 54 formed near the end of the strap 52, and the grasping tab 58 extends beyond an end portion 56 of the strap 52. The grasping element 58 includes a gripping tab 59 extending outwardly therefrom.

The grasping element may be formed from a polymeric material that allows for easy gripping of the strap and may be flexible rather than rigid or semi-rigid. The grasping element also reinforces the end portion of the strap, thereby protecting the end portion of the strap and allowing it to more easily extend through a slot or attach to structure, in combination with the hook material 54.

FIG. 6 depicts a strapping system 60 located on a frame element of an orthopedic device 61, such as in an orthopedic walker. In this embodiment, the strapping system 60 includes first and second straps 62, 64 that are embedded in a substantially rigid strut belonging to the orthopedic device 61. Advantageously, an intermediate portion of the straps 62, 64 is embedded and locked in place along the strut at location 66. Such an arrangement prevents shifting of the straps when a user wears the orthopedic device. Of course, it will be understood that the strapping system 60 is not limited to the orthopedic device shown herein by may be used in a variety of orthopedic frame elements, whether they are rigid or flexible.

In another embodiment, a strapping system 70 is shown in FIGS. 7A and 7B as having a track 75. The strapping system 70 involves first and second straps 72, 74 that are coupled by the block track 75 integrally and inseparably mounted on the second strap 74. The block track 75 defines a slot 76 extending through the length of the block track 75, and sized to permit sliding of the first strap 72 relative to the second strap 74.

FIG. 8 describes a variation of a strapping system 80 having an elongate track 85 having an elongate slot 86. The elongate track 85 is integrally and inseparably mounted on a first strap 82. A mount 87 having a pin 88 extending therefrom is integrally and inseparably mounted on a second strap 84. The pin 88 is arranged to slidably engage the elongate slot 86 so as to permit the second strap 84 to slide relative to the first strap 82.

FIG. 9 illustrates another strapping system embodiment 90 including a strap 92 having an end portion 94 embedded into a D-ring 95 having an integrally molded loop. The D-ring 95 is integrally and inseparably mounted onto the end portion 94. The D-ring 95 defines an opening for engaging with another strap. This embodiment removes the necessity to stitch or otherwise mount a D-ring onto a strap.

FIG. 10 depicts another strapping system embodiment 100 having a strap 102 with a stopper 104 integrally and inseparably mounted onto an intermediate portion 103 of the strap 102. The strapping system 90 is shown as being secured to the strap 102, with the stopper 104 preventing movement of the strapping system 90 beyond the intermediate portion 103.

FIG. 11 exemplifies another strapping system embodiment 110 having a buckle element 116 integrally and inseparably mounted at an end portion 114 of a strap 112. The buckle 116 may take form of a variety of known plastic based buckles, such as one with prongs 115, and arranged to engage an opposing strap system (not shown) having a corresponding buckle element.

FIGS. 12A and 12B illustrate another strapping system embodiment 120 that can be secured to a structure 124 or another strapping system. FIG. 12A shows a first configuration including a strap 122 defining an end portion 123 that is integrally and inseparably secured to a connection tab 125. The connection tab 125 is formed from a polymeric material and includes a stake 126 protruding from a surface of the tab 125. In this first configuration, the stake 126 is arranged to extend through an opening 127 formed through the structure 124, and have an end portion 129 protrude a distance beyond the opening 127.

FIG. 12B depicts a second configuration of the strapping system 120 wherein heat is applied to the end portion 129 so as to deform the end portion 129 in a manner that it includes a flange 128. The flange 128 effectively locks the strapping system 120 to the structure 124.

FIG. 13 exemplifies another strapping system 130 including a strap 132 having an end portion 133 integrally and inseparably secured to locking tab 134. The locking tab 134 forms a plurality of serrations effectively forming a ladder ratchet 136. This embodiment can replace the ladder strap described in U.S. Pat. No. 7,198,610, incorporated herein by reference in its entirety, by eliminating the need to stitch a strap onto a ladder ratchet.

FIG. 14 illustrates yet another strapping system 140 including an attachment tab 144 carrying a plurality of hook elements 146. The attachment tab 144 is secured to an end portion 143 of a strap 142 in the manner described above in connection with the first embodiment.

The attachment tab 144 may include a malleable element 148 permitting the attachment tab 144 to flex and maintain a configuration to correspond to an anatomical portion. The attachment tab 144 may be formed in at least an open configuration 144A and a closed configuration 144B. The malleable element 148 may be an aluminum stay, whereas the attachment tab may be formed from a flexible polymeric material.

The hook elements 146 may be formed integrally with the attachment tab 144, or in the alternative, the hook elements may be formed separately from the attachment tab and secured therewith.

FIG. 15 shows another strapping system 150 wherein end portions 154A, 154B of opposed straps 152A, 152B are integrally and inseparably joined by a pad 155. The pad 155 includes an imprint 156 with indicia, which is formed by the material of the pad.

FIG. 16A depict another strapping system 160 including a strap 162 and spring element 164 integrally and inseparably secured to a pad 166. The spring element 164 may be a leaf spring formed from a resilient material such as a metal or polymer.

FIG. 16B illustrates the strapping system 160 secured to a structure 168, exemplified by an orthopedic walker, via a fastener 169. In this portrayal, the pad 166 encases the spring element and an end portion of the strap. The strapping system is preferably mounted along an edge of the structure and permits the strapping system to bend and yet return to a predetermined shape when the strap is not attached to any other structure.

FIG. 17 describes another strapping system 170 having first and second straps 172, 173 coupled by an elastic element 175. As with the embodiments described above, the end portions 174 of the straps 172, 173 are integrally and inseparably secured to the elastic element 175. The elastic element 175 permits the straps 172, 173 to be pulled away from one another, thereby allowing the strapping system 170 to stretch.

FIG. 18 shows another strapping system 180 having first and second straps 182, 183 having end portions 184 integrally and inseparably secured to an elastic element 185. The elastic element 185 has a tapered width 186 facilitating stretching with the minimum width 187 located at a center portion of the elastic element 185.

In both of the strapping system embodiments 170, 180, the elastic elements may be formed from a substantially elastic polymeric material.

In reference to FIGS. 19A and 19B, the strapping system 190 includes a strap 192 having an end portion 193 integrally and inseparably secured to a pad element 194 having a complex shape. In particular, the pad element 194 defines a padding portion 195 with a strap 196 depending therefrom and including grasping tabs 198. The padding portion 195 has a width and thickness larger than the strap 192 and the pad strap 196.

In an exemplary method, the strapping system includes the steps of placing a strap having locking elements in a mold, closing the mold to inject a heated polymeric material onto the locking elements, allowing the polymeric material to cool, opening the mold and removing the formed strapping system from the mold, and trimming off any runners, flash or excess. It is preferred that the strap be placed in a flat configuration in the mold so that the plastic does not flow to a side of the strap not carrying the locking elements.

While the foregoing embodiments have been described and shown, it is understood that alternatives and modifications of these embodiments, such as those suggested by others, may be made to fall within the scope of the invention. Moreover, any of the principles described herein may be extended to any other orthopedic devices or devices requiring a reinforced strap. 

1. A strapping system, comprising: a flexible, textile strap having locking elements, and defining an attachment portion; and a reinforcement element inseparably and integrally secured to the attachment portion of the strap, the locking elements of the strap being embedded at least in part into the thickness of a reinforcement element.
 2. The strapping system according to claim 1, wherein the locking elements are formed along a single side of the strap.
 3. The strapping system according to claim 1, wherein the reinforcement element is secured to a first side of a first end portion of the strap.
 4. The strapping system according to claim 1, wherein the reinforcement element is secured to first and second sides of a first end portion of the strap.
 5. The strapping system according to claim 1, wherein an opening extends through a thickness of the reinforcement element and the strap.
 6. The strapping system according to claim 1, wherein the reinforcement element includes a traction texture formed by a solid mass of molded polymeric material.
 7. The strapping system according to claim 1, wherein the reinforcement element is flexible.
 8. The strapping system according to claim 1, wherein a first surface of the reinforcement element includes plurality of gripping tabs extending therefrom.
 9. The strapping system according to claim 1, wherein the reinforcement element is contoured in a predetermined shape, the reinforcement element being flexible and resiliently bending from the predetermined shape to an additional shape upon the exertion of a force, the reinforcement element returning to the predetermined shape upon removal of the force.
 10. The strapping system according to claim 1, wherein the strap is substantially more flexible than the reinforcement element.
 11. The strapping system according to claim 1, wherein the reinforcement element is substantially compressible.
 12. The strapping system according to claim 11, wherein the reinforcement element has at least one protrusion extending therefrom, the reinforcement element secured to a free end portion of a strap.
 13. The strapping system according to claim 1, wherein the reinforcement element is an elongate frame element formed from a substantially rigid material.
 14. The strapping system according to claim 1, wherein the reinforcement element has an arcuate shape in a first configuration formed as at least part of a cuff, the cuff being resilient to bending upon application of a force and substantially returning to the first configuration upon release of the force.
 15. The strapping system according to claim 1, wherein the reinforcement element forms a structure and secures to a generally intermediate portion of a strap, the structure forming a slot permitting the extension of a second strap therethrough.
 16. The strapping system according to claim 1, wherein the reinforcement element forms a structure and secures to a generally intermediate portion of a strap, the first structure forming at least one slot along an exterior side thereof, a second strap including a second structure having an engaging element arranged to slidably interlock with the slot of the first structure.
 17. The strapping system according to claim 1, wherein the reinforcement element forms a structure encasing opposed sides of the strap along an intermediate portion of the strap.
 18. A strapping system, comprising: a flexible strap having a reinforced portion defining a plurality of locking elements; and a reinforcement element inseparably and integrally secured to the reinforced portion of the strap, the locking elements of the strap being embedded at least in part into the thickness of a reinforcement element; wherein the reinforcement element is contoured in a predetermined shape, the reinforcement element being flexible and resiliently bending from the predetermined shape to an additional shape upon the exertion of a force, the reinforcement element returning to the predetermined shape upon removal of the force.
 19. The strapping system according to claim 18, wherein the reinforcement element defines a traction texture.
 20. A strapping system, comprising: a flexible textile strap having a reinforced portion defining a plurality of locking elements; and a reinforcement element inseparably and integrally secured to the reinforced portion of the strap, the locking elements of the strap being embedded at least in part into the thickness of a reinforcement element; wherein the reinforcement element is contoured in a predetermined shape and is formed from a solid mass of molded polymeric material, the reinforcement element being flexible and resiliently bending from the predetermined shape to an additional shape upon the exertion of a force, the reinforcement element returning to the predetermined shape upon removal of the force. 